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E-Bike Transmission Design

For our spring semester innovation scholars project, the three of us decided to research electric drivetrains. We centered our design around the bike platform, and creating a modular e-bike drivetrain that can be fitted to various frames. We looked into different types of motors, and selected a heavy duty brushless drone motor. This kept the electronics simple and robust, but we needed to reduce the output RPM. This led to the main phase of our project, where we looked into various transmission designs, and created one that suited our needs as well as tested manufacturing methods that we wanted to learn about. We learned a lot about the application of different tolerances and fits, and needed to modify our designs based on the methods of manufacture we chose. During our construction, we waterjet cut parts, 3D printed parts, and combined them with purchased fasteners, as well as techniques such as welding, to create our final product. Our testing then showed us why some of these methods were correctly used, some less-so, and why industry designs use certain manufacturing methods over others.

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